Page 1 of 37

21-1

Charge air system with
turbocharger

Turbocharger, removing and installing

Observe rules for cleanliness Page 21
-8 .

Notes:

Turbochargers must be replaced in pairs.
Manufacturing tolerances may prevent matched
operation.
All hose connections are secured with clips.
Charge air system must be free of leaks.
Replace self-locking nuts.
Replace all seals and gaskets

Page 6 of 37

Installing
Notes:
When installing turbocharger, be sure that o-ring at connection flange for
oil return is not damaged. - Disconnect oil return line -1-.
- Disconnect water line -2-.
- Remove turbocharger -3- (3 bolts).
- Installation is the reverse of removal.

The text "Abgasturbocharger" must be readable as shown in illustration,
install turbocharger hose -1- properly if necessary.
The hose clamps -2- must be installed as shown in illustration. The bolt-
locks on the screw clamps must be placed at the X-marking on the hose.
Pa
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ge air s
ystem with turbochar
ger
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.21.1

Page 8 of 37

21-8

Rules for cleanliness

When working on the exhaust gas turbocharger,
pay careful attention to the following 5 rules:

Thoroughly clean all unions and the adjacent
areas before disconnecting.
Place parts that have been removed on a clean
surface and cover. Do not use fluffy cloths!
Carefully cover opened components or seal, if
the repair cannot be carried out immediately.
Only install clean components: Only unpack
replacement parts immediately prior to
installation. Do not use parts that have been
stored loose (e.g. in tool boxes etc.).
When the system is open: Do not work with
compressed air if this can be avoided. Do not
move vehicle unless absolutely necessary.
Pa
ge 8 of 37 Char
ge air s
ystem with turbochar
ger
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.21.1

Page 9 of 37

21-9

Turbocharger and charge pressure
regulating valve, checking

Safety notes
Note the following points if test equipment has to
be used during a road test:

WARNING!

Test equipment must always be secured on
the rear seat and operated from there by a
second person.
If test equipment is operated from the front
passenger seat, the occupant could be
injured by the passenger's airbag in an
accident.